Raw Material Formulation and Pre-treatment

Main Material: Polyvinyl chloride (PVC) resin powder (accounting for 50%–70%); suspension-grade or emulsion-grade resin is selected based on the product type.
Auxiliary Materials: Plasticizers (DOP/epoxidized soybean oil to enhance flexibility), stabilizers (eco-friendly calcium-zinc types replacing traditional lead salts), calcium carbonate filler (to reduce costs and increase hardness), flame retardants (aluminum hydroxide), and pigments (color powder or masterbatch).
Pre-treatment: Raw materials undergo screening and drying (moisture content ≤0.3%) before being precisely weighed according to the formula to ensure batch consistency.

High-Speed ​​Mixing and Plasticization
Mixing: Raw materials are fed into a high-speed mixer (rotation speed ≥1000 rpm) and heated to 100–120°C, allowing the PVC resin and plasticizer to melt fully and form a uniform paste.
Plasticization: The mixture is transferred to an internal mixer or twin-screw extruder for further plasticization at 150–180°C, eliminating air bubbles and increasing material density.

Molding Process
(1) Calendering Method (Sheet/Roll Flooring)
Multi-layer Lamination: The plasticized PVC material passes through a multi-roll calender (roll temperature 160–190°C) to sequentially form the base layer (foamed layer), printed layer, and wear layer (transparent PVC + aluminum oxide).
Foamed Layer Processing: The base layer expands in a foaming oven (200–220°C) to form an elastic closed-cell structure with a density of 0.6–0.9 g/cm³.
(2) Extrusion Method (Plank/Tile Flooring)
Co-extrusion Molding: A multi-layer co-extrusion die is used to simultaneously extrude the wear layer, printed layer, and core layer (high-density PVC + fiberglass mesh reinforcement); the material is cooled by sizing rollers and then cut into base boards. 4. Surface Treatment
UV Coating: A UV-curable coating (0.2–0.5 mm thick) is applied to the wear layer via curtain coating or roller coating to enhance scratch resistance (achieving Class T wear resistance).
Embossing: Steel roller embossing or laser engraving is used to replicate 3D textures-such as wood grain or stone-while simultaneously improving slip resistance (Class R9 in wet conditions).

Post-processing and Quality Inspection
Stabilization (Aging): Finished products are allowed to rest in a climate-controlled environment (constant temperature and humidity) for 48 hours to release internal stress and prevent deformation.
Quality Inspection: Testing includes wear resistance (Taber method), locking system tensile strength (≥1500 N/m), and fire rating (Class B1 via cone calorimeter); products are packaged and warehoused only after passing inspection.